Method And System For Conveying Articles

ABSTRACT

A method of conveying articles includes moving a first plurality of articles in a first input lane and a moving second plurality of articles in a second input lane in a downstream direction to a lane combiner, and operating the lane combiner to combine the first plurality of articles and the second plurality of articles into a combined plurality of articles in an output lane. The operating the lane combiner includes engaging a first article from the first plurality of articles with a first combiner wheel, engaging a second article from the second plurality of articles with a second combiner wheel that is out of phase with the first combiner wheel, rotating the first combiner wheel and the second combiner wheel to move the first article and then the second article into the output lane, the combined plurality of articles includes the first article and the second article in sequence.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of each of U.S. Provisional PatentApplication No. 62/746,212, filed on Oct. 16, 2018, and U.S. ProvisionalPatent Application No. 62/786,798, filed on Dec. 31, 2018.

INCORPORATION BY REFERENCE

The disclosures of each of U.S. Provisional Patent Application No.62/746,212, filed on Oct. 16, 2018, and U.S. Provisional PatentApplication No. 62/786,798, filed on Dec. 31, 2018, are herebyincorporated by reference as if presented herein in their entirety andare incorporated by reference for all purposes.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to systems and methods forconveying articles in a packaging machine. More specifically, thepresent disclosure is directed to methods and systems for combiningmultiple feeds of the articles prior to loading the articles intocartons.

SUMMARY OF THE DISCLOSURE

According to one aspect of the disclosure, a method of conveyingarticles comprises moving a first plurality of articles in a first inputlane in a downstream direction to a lane combiner, moving a secondplurality of articles in a second input lane in the downstream directionto the lane combiner, and operating the lane combiner to combine thefirst plurality of articles and the second plurality of articles into acombined plurality of articles in an output lane. The operating the lanecombiner comprises engaging a first article from the first plurality ofarticles with a first combiner wheel, engaging a second article from thesecond plurality of articles with a second combiner wheel that is out ofphase with the first combiner wheel, rotating the first combiner wheelto move the first article into the output lane, rotating the secondcombiner wheel to move the second article into the output lane after thefirst article, and the combined plurality of articles comprises thefirst article and the second article in sequence.

According to another aspect of the disclosure, a system for conveyingarticles comprises a first input lane, a second input lane, and a lanecombiner positioned downstream from the first input lane and the secondinput lane and comprising a first combiner wheel that is out of phasewith a second combiner wheel. The first combiner wheel is positioned toengage a first article from a first plurality of articles in the firstoutput lane and the second combiner wheel is positioned to engage asecond article from a second plurality of articles in the second inputlane. Upon out of phase rotation of the first combiner wheel and thesecond combiner wheel, the first article is moved into the output laneand the second article is moved into the output lane after the firstarticle to form a combined plurality of articles that comprises thefirst article and second article in sequence.

According to another aspect of the disclosure, a lane combiner comprisesa first combiner wheel and a second combiner wheel that is out of phasewith a second combiner wheel. The lane combiner is positioned downstreamfrom a first input lane and a second input lane such that the firstcombiner wheel is positioned to engage a first article from a firstplurality of articles in the first output lane and the second combinerwheel is positioned to engage a second article from a second pluralityof articles in the second input lane. Upon out of phase rotation of thefirst combiner wheel and the second combiner wheel, the first article ismoved into the output lane and the second article is moved into theoutput lane after the first article to form a combined plurality ofarticles that comprises the first article and second article insequence.

Additional aspects, features, and advantages of the present inventionwill become apparent from the following description and accompanyingfigures.

BRIEF DESCRIPTION OF THE DRAWINGS

Those skilled in the art will appreciate the above stated advantages andother advantages and benefits of various additional embodiments readingthe following detailed description of the embodiments with reference tothe below-listed drawing figures. It is within the scope of the presentdisclosure that the above-discussed aspects be provided bothindividually and in various combinations.

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the disclosure.

FIG. 1 is a schematic plan view of a system for conveying articlesaccording to a first exemplary embodiment of the disclosure.

FIG. 2 is a schematic elevation view of an article for being conveyed bythe system of FIG. 1 according to the first exemplary embodiment of thedisclosure.

FIG. 3 is a schematic perspective view of a lane combiner apparatus ofthe system of FIG. 1 according to an exemplary embodiment of thedisclosure.

FIG. 4 is a schematic perspective view of a system conveying articlesaccording to a second exemplary embodiment of the disclosure.

FIG. 5 is another schematic perspective view of the system of FIG. 4,with portions thereof shown in phantom lines.

FIG. 6 is a schematic perspective view of a lane combiner of the systemof FIG. 4.

FIG. 7 is a schematic perspective view of a combiner wheel of the systemof FIG. 4.

FIG. 8 is a schematic plan view of the combiner wheels of the system ofFIG. 4.

FIG. 9 is a schematic plan view of the combiner wheels of FIG. 8engaging articles in the lane combiner of FIG. 6.

FIG. 10 is another schematic plan view of the combiner wheels of FIG. 8engaging articles in the lane combiner of FIG. 6.

Corresponding parts are designated by corresponding reference numbersthroughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure generally relates to a system and method ofconveying or feeding articles prior to loading the articles into cartonsin a packaging machine. The system according to the present disclosurecan accommodate articles of any shape. The articles can be containers,bottles, cans, etc. The articles can be used for packaging food andbeverage products, for example. The articles can be made from materialssuitable in composition for packaging the particular food or beverageitem, and the materials include, but are not limited to, aluminum and/orother metals; glass; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS,PVC, EVOH, and Nylon; and the like, or any combination thereof.

FIG. 1 generally illustrates an example embodiment of a system andmethod 100 for conveying/arranging articles or containers C (FIG. 2),for example, for being loaded into cartons in accordance with thedisclosure. In one embodiment, the system 100 can be included in acontinuous packaging machine for packaging the articles C for storage,shipping, sale, etc. For example, the packaging machine can continuouslyor substantially continuously feed articles C to the system 100, whichconveys the articles C as described below, which can then betransferred, for example, to a carton or container to form a package.

In the illustrated embodiment, the articles C (e.g., as shown in FIGS.1-4) can be in the form of tubs, cups, pods, etc. having tapered sides Sso that the articles C are narrower at their bottoms B than at theirtops T. In this regard, the tops T of the respective articles C define afirst diameter that is larger than a second diameter defined by therespective bottoms B of the respective articles C.

The top T of each article C can have a rim R and a lid L (e.g., a foil,film, covering, or other suitable lid) that can seal the top T at therim R. In one exemplary embodiment, the articles C can be for containinga product for brewing a beverage (e.g., coffee, tea, cocoa, etc.) fromgranulized solids in a single-cup brewing system (e.g., K-Cup pods forsingle-cup brewing systems available from Keurig Dr. Pepper ofBurlington, Mass., or other suitable containers and systems).

In the illustrated embodiment, the system 100 includes a lane combiner101, receives the articles C from two inputs (not shown) at an upstreamend 103 of the system 100, and conveys the articles C to the downstreamend 105 of the system 100 in a machine direction M. In one embodiment,the articles C fed from the first input can be a first plurality ofarticles each designated CD and having a foil down orientation (e.g.,with the lid L facing downwardly) in a first input lane 107 and thearticles fed from the second input can be a second plurality of articleseach designated CU and having a foil up orientation (e.g., with the lidL facing upwardly) in a second input lane 109. In one embodiment, thearticles CD and the articles CU can be considered to have invertedorientations relative to one another.

The lane combiner 101 can be obtained and used to move the articles CD,CU from the respective input lanes 107, 109 into a output lane 111 sothat the articles CD from the first input lane 107 alternate with thearticles CU from the second input lane 109 and so that the articles CD,CU alternate between the foil down and foil up orientations in theoutput lane 111 in a combined plurality of articles 112. In oneembodiment, a first sequential article in the output lane 111 in themachine direction M is one of an article CU of CD, and every otherfollowing article (e.g., a third sequential article, a fifth sequentialarticle, etc.) is an article of the same configuration. In an exemplaryembodiment, the articles CD, CU can move in the output lane 111 toanother portion of a packaging machine to be loaded into cartons. Asdescribed herein, the input lanes 107, 109 are each in communicationwith and positioned upstream relative to a combination area 158 that isin communication with and positioned upstream from the output lane 111.

As shown in FIG. 1, the first input lane 107 can include a first outerlane guide 121 and a first inner lane guide 123, and the second inputlane 109 can include a second outer lane guide 125 and a second innerlane guide 127. In the illustrated embodiment, the input lanes 107, 109are initially spaced apart at the upstream end 103 of the system 100 andportions of the input lanes 107, 109 are angled toward one anotherupstream from the lane combiner 101 so that the outer lane guides 121,125 are angled inwardly and such that the inner lane guides 123, 127converge at a divider 129. In an exemplary embodiment, the divider 129can extend from and/or be integral with one of the inner lane guides123, 127.

In one embodiment, the articles CD, CU can move in the input lanes 107,109 on respective input conveyors (e.g., conveyor belts or any othersuitable conveyor) to the lane combiner 101. In the illustratedembodiment, as the input lanes 107, 109 converge toward the divider 129,the lane guides 121, 123 and 125, 127 can guide the respective articlesCD, CU onto a main conveyor 131, which can move the articles from therespective input lanes 107, 109, through the combination area 158, andinto the output lane 111. In one example, the input conveyors can bemarginal portions of the main conveyer 131 or can be otherwise disposedon either side of the main conveyor 131 extending near the upstream end103. In one embodiment, and with additional reference to FIG. 4, themain conveyor 131 can include a belt 132 or other suitable conveyordriven by a motor 133 via wheels or gears 135 and can be supported onsupports 137 (e.g., the belt 132 can slide along supports 137 as itmoves in the machine direction M), as shown best in FIG. 5.

Still referring to FIG. 1, the articles CD, CU are moved in the machinedirection M in the respective lanes 107, 109 on the main conveyor 131with the divider 129 extending between the lanes. Any of the input lanes107, 109 and/or the main conveyor 131 could be omitted or could beotherwise shaped, positioned, arranged, and/or configured withoutdeparting from the disclosure.

In the illustrated embodiment, the lane combiner 101 can include a firststar wheel or first combiner wheel 141 (e.g., that engages the foil downarticles CD from the first input lane 107) and a second star wheel orsecond combiner wheel 143 (e.g., that engages the foil up articles CUfrom the second input lane 109) that are positioned in the combinationarea 158. The combiner wheels 141, 143 are positioned on opposite sidesof the lane combiner 101 along a lateral axis L1 (e.g., that extendstransversely across the width of the main conveyor 131, generallyperpendicular to the machine direction M). Each of the combiner wheels141, 143 has a plurality of peaks 145 and a plurality of recesses 147interposed with the peaks 145. In one embodiment, the recesses 147 canbe curved to complement the curved sides S of the articles C and thepeaks 145 of each combiner wheel 141, 143 can be spaced from therespectively adjacent peaks 145 so that the recesses 147 are sized toreceive and engage a respective article CD, CU (e.g., so that the recess147 contour or otherwise extends partially around the side S of thearticle).

As shown in FIG. 1, the combiner wheels 141, 143 each have six peaks 145and six recesses 147. Alternatively, the combiner wheels 141, 143 couldhave any suitable number of peaks 145 and recesses 147. While thecombiner wheels 141, 143 are illustrated having a generally symmetricalarrangement, one or more of the combiner wheels 141, 143 could includean asymmetrical portion(s).

In the illustrated embodiment, the combiner wheels 141, 143 rotate onrespective generally parallel axes 149 (broadly, respective “firstrotational axis” and “second rotational axis”) and extend into thedownstream ends of the input lanes 107, 109 through the respective outerlane guides 121, 125 (e.g., through respective slots 151 in the outerlane guides 121, 125 as shown in FIG. 3). In one embodiment, thecombiner wheels 141, 143 can be mounted on a respective axel or shaftthat defines the respective axis 149, and are rotated by a motor 153(FIG. 3) via gears or other actuating structure so that the firstcombiner wheel 141 rotates in a counterclockwise direction as viewedfrom above and the second combiner wheel 143 rotates in a clockwisedirection as viewed from above as shown in FIG. 1. Accordingly, thepeaks 145 and the recesses 147 of the combiner wheels 141, 143 each movein the machine direction M at portions thereof disposed in therespective input lanes 107, 109.

As shown in FIG. 1, the combiner wheels 141, 143 are out of phase withrespect to one another. For example, one of the peaks 145 of the secondcombiner wheel 143 can move through the second input lane 109 atapproximately the same time that the midpoint of one of the recesses 147of the first combiner wheel 141 moves through the first input lane 107.In this regard, at a selected moment in time, the first combiner wheel141 can be positioned at a first rotational orientation RP1 about therespective axis 149 in which a first recess 147 of the first combinerwheel 141 is positioned in the combination area 158 and is offset from asecond recess 147 of the second combiner wheel 143 that is positioned inthe combination area 158 when the second combiner wheel 143 ispositioned at a second rotational orientation RP2 about the respectiveaxis 149 that is different from the first rotational orientation RP1. Inone embodiment, when the first recess 147 of the first combiner wheel141 is positioned in the combination area 158, a peak 145 of the secondcombiner wheel 143 extends at least partially across the second inputlane 109. Similarly, in one embodiment, when the first recess 147 of thesecond combiner wheel 143 is positioned in the combination area 158, apeak 145 of the first combiner wheel 141 extends at least partiallyacross the first input lane 107.

Accordingly, in one embodiment, the first combiner wheel 141 is arrangedfor receiving a foil down article CD (broadly, “first article”) from thefirst input lane 107 in the first recess 147 and moving the firstarticle CD into the output lane 111, which can be sequentially followedby a foil up article CU (broadly, “second article”) from the secondinput lane 109 that can be received and engaged by the second combinerwheel 143 and moved into the output lane 111 after the first article CD.The lane combiner 101 could be otherwise shaped, positioned, arranged,and/or configured without departing from the disclosure.

In the illustrated embodiment, the output lane 111 can includerespective first and second lane guides 155, 157 that can at leastpartially define a combination area 158 therebetween that includes afunnel portion 159 at an upstream end of the output lane 111 that canconverge in the machine direction M to accommodate the width of thearticles CD, CU in the output lane 111. The funnel portion 159 includesa respective first sloped surface and a second sloped surface defined bythe respective lane guides 155, 157 and that are arranged to convergetoward one another. As shown in FIG. 1, the upstream ends of the laneguides 155, 157 are positioned to be proximate the downstream ends ofthe respective outer lane guides 121, 125 of the input lanes 107, 109.In one embodiment, the downstream ends of the outer lane guides 121, 125can overlap the upstream ends of the lane guides 155, 157. In oneembodiment, the lane guides 155, 157 can be extensions of the respectivelane guides 121, 125.

As shown in FIG. 1, the articles CD, CU can move along the respectivelane guides 155, 157 in the funnel portion 159 from the respectivecombiner wheels 141, 143 on the belt 132 of the main conveyor 131. Oncethe lane guides 155, 157 converge, the articles CD, CU can move alongone or both of the lane guides 155, 157 as they guide the articles inthe output lane 111 to an output conveyor 161 and to the downstream end105 of the system 100. The output conveyor 161 can be a belt conveyor orany other suitable conveyor apparatus. The output lane 111 and/or theoutput conveyor 161 could be otherwise shaped, positioned, arranged,and/or configured without departing from the disclosure.

In operation, the foil down articles CD move in the first input lane 107from the upstream end 103 of the system 100 along one or both of thelane guides 121, 123 onto the main conveyor 131. Similarly, the foil uparticles CU move in the second input lane 109 from the upstream end 103along one or both of the lane guides 125, 127 onto the main conveyor131. In the illustrated embodiment, as the articles CD, CU move on themain conveyor 131 in the machine direction M, the articles move past thedownstream end of the inner lane guides 123, 127 (e.g., where the innerlane guides 123, 127 converge at the divider 129) and then the foil downarticles CD move between the outer lane guide 123 and the divider 129and the foil up articles CU move between the outer lane guide 125 andthe divider 129. The articles CD, CU continue to move on the mainconveyor 131 through the lane combiner 101 where the foil down articlesCD in the first input lane 107 sequentially engage the first combinerwheel 141 and the foil up articles CU in the second input lane 109sequentially engage the second combiner wheel 143.

In one embodiment, one of the foil down articles CD can engage a peak145 of the first combiner wheel 141 as that peak 145 moves into thefirst input lane 107 (e.g., see the article CD in position P1 in FIG.1). As that peak 145 moves through the first input lane 107, the mainconveyor 131 urges the foil down article CD in the machine direction Mso that the article CD engages, e.g., is at least partially received by,a recess 147 adjacent the peak 145 that is moving through the firstinput lane 107 (e.g., see the article CD in position P2 in FIG. 1). Thefoil down article CD in the position P2 is now received in the recess147 between two peaks 145 and is moved in the first input lane 107 bythe first combiner wheel 141 as the recess 147 moves through the firstinput lane 107.

In one embodiment, the combiner wheels 141, 143 can rotate at a rate sothat the articles CD, CU are moved by the respective combiner wheels141, 143 at a different speed than the belt 132, (e.g., the combinerwheels 141, 143 can move the articles slower or faster than the belt132). In this regard, the main conveyor 131 can move faster than thecombiner wheels 141, 143 so that the articles CD, CU move faster in thefunnel portion 159 of the output lane 111 than the articles CD, CU inthe lane combiner 101, e.g., because the rotational engagement of thecombiner wheels 141, 143 with the respective articles CD, CU regulatesthe linear speed of the articles CD, CU, which can cause the articlesCD, CU to slide along the belt 132 when engaged with the respectivecombiner wheels 141, 143. Such a configuration can be provided, forexample, to provide clearance between one or more articles to facilitatepositioning of articles on the system 100, to form product groupings ofpreselected number/size, to accommodate disparate timing of componentsof the system 100, to provide opportunities for visual inspection ormanual adjustment, etc. Alternatively, the combiner wheels 141, 143 canmove the articles at a similar or same rate as the belt 132.

In one embodiment, the main conveyor 131 can move faster than thecombiner wheels 141, 143 so that the articles CD, CU move faster in thefunnel portion 159 of the output lane 111 than the articles CD, CU inthe lane combiner 101 (e.g., because the rotational engagement of thecombiner wheels 141, 143 with the respective articles CD, CU regulatesthe linear speed of the articles CD, CU). This faster movement of thearticles CD, CU in the output lane 111 can help provide clearancebetween the articles in the output lane 111 and the subsequent articlereleased by the combiner wheels 141, 143.

Once the leading peak 145 of the recess 147 that is engaging the articleCD rotates out of the first input lane 107, the article CD can move outof the recess 147 and into the funnel portion 159 of the output lane 111on the main conveyor 131 (e.g., see the article CD in the position P3 inFIG. 1). In the illustrated embodiment, while the first combiner wheel141 is moving a particular foil down article CD in the first input lane107 (e.g., the article CD in position P2 in FIG. 1), the second combinerwheel 143 receives in a respective recess 147 a particular foil uparticle CU that is slightly upstream with respect to that foil downarticle CD (e.g., the article CU in position P4 is slightly upstreamfrom the article CD in position P2 in FIG. 1). As the article CD ismoved into the output lane 111 (e.g., the article CD in position P3 inFIG. 1), the second combiner wheel 143 is moving the foil up article CU(e.g., in position P5 in FIG. 1) in the second input lane 109 intoposition to be moved into the output lane 111 subsequent to the articleCD in position P3.

In this regard, with respect to the foil up article CU in position P5,the peak 145 of the second combiner wheel 143 that is retaining thatarticle in the recess 147 is moving through the slot 151 in the outerlane guide 125 as shown in FIG. 1 so that the main conveyor 131 can movethe article CU in position P5 out of the recess 147 and into the outputlane 111 subsequent to the article CD in position P3 that was previouslymoved into the output lane 111.

In the illustrated embodiment, the aforementioned out of phase rotationof the combiner wheels 141, 143 combines and moves the articles CD, CUinto the output lane 111 from the first input lane 107 and then from thesecond input lane 109 so that the articles CD, CU alternate in sequencein the output lane 111 between foil down articles CD from the firstinput lane 107 and foil up articles CU from the second input lane 109 toform the combined plurality of articles 112. The main conveyor 131 canmove the combined plurality of articles 112 into the output lane 111,which can then move the alternating articles CD, CU in the downstreamdirection to the output conveyor 161 to the downstream end 105 of thesystem 100. Subsequently, the articles can be further processed (e.g.,wrapped, loaded into cartons, etc.).

It will be understood that the above-described operation of the lanecombiner 101 that moves a first article CD from the first input lane 107into the output lane 111 sequentially followed by a second article CUfrom the second input lane 109 can be repeated any desired number oftimes, e.g., such that a third article CD from the first input lane 107is engaged by the first combiner wheel 141 and moved into the outputlane 111 sequentially behind the second article CU and such that afourth article CU from the second input lane 107 is engaged by thesecond combiner wheel 143 and moved into the output lane 111sequentially behind the third article CD, etc.

The articles CD, CU could be otherwise combined into a single lanewithout departing from the disclosure. For example, the foil up articlesCU could be moved in the first input lane 107 and the foil down articlesCD could be moved in the second input lane 109 (e.g., as shown in FIG.3). In another example, the lane combiner 101 could be configured tomove more than one article at a time from each input lane 107, 109(e.g., so that orientation of the articles in the output lane 111alternates at every two or more articles).

FIG. 5 is an isometric view of a conveyor portion of a system and method300 for conveying/arranging articles or containers C for being loadedinto cartons (not shown) according to a second exemplary embodiment ofthe disclosure. The second exemplary embodiment can include one or morefeatures that are substantially the same or substantially similar tothose described above with regard to the first exemplary embodiment, andlike or similar features are designated with like or similar referencenumbers.

As shown in FIGS. 5 and 6, the system 300 has a lane combiner 301 withrespective first and second combiner wheels 341, 343 that can have adifferent configuration than the combiner wheels 141, 143 of the firstexemplary embodiment. In addition, the combiner wheels 341, 343 arepositioned closer together in a combination area 359 of the lanecombiner 301. It will be understood the combiner wheels 341, 343 canhave a different configuration and/or positioning without departing fromthe disclosure.

As described herein, the input lanes 107, 109 are each in communicationwith and positioned upstream relative to a combination area 359 that isin communication with and positioned upstream from an output lane 311.In this regard, the first plurality of articles CD and the secondplurality of articles CU can be moved in a downstream direction to thelane combiner 301 in a manner similar to that described above withregard to the system 100.

The output lane 311 of the system 300 can include respective first andsecond lane guides 355, 357 that at least partially define thecombination area 359 therebetween and do not include the funnel portionof the first exemplary embodiment. Rather, the arrangement of thecombiner wheels 341, 343 in the combination area 359 can obviate anyadditional need for a funnel portion, as described further below.

As shown in FIGS. 5 and 6, the combination area 359 of the lane combiner301 is defined at a downstream end 363 of the divider 329 and betweenthe outer lane guides 121, 125. In one embodiment, the outer lane guides121, 125 can include cutouts 351 extending to their respectivedownstream ends 367, and the cutouts 351 can be configured such that atleast a portion of the respective the combiner wheels 341, 343 extendtherethrough.

Two guide brackets 369, 371 can extend along the combination area 359from the upstream ends of the lane guides 355, 357 of the output lane311 to the downstream ends 367 of the outer lane guides 121, 125 and canoverlap with portions of the outer lane guides 121, 125. Each of theguide brackets 369, 371 can include two plates 373 connected by a spacerelement 375. In one embodiment, the spacer element 375 can be connectedto the upstream end of the respective lane guide 355, 357. The spacerelement 375 can form a gap between the plates 373 to provide clearancefor the respective combiner wheels 341, 343. Each of the plates 373 caninclude/define a respective sloped edge 377 (broadly, respective “firstsloped surface” and “second sloped surface”) that are arranged toconverge toward one another and that can guide the articles CD, CU fromthe combination area 359 to the output lane 311 as the combiner wheels341, 343 move the articles CD, CU through the combination area 359.

The first combiner wheel 341 is shown in FIG. 9 and includes a pluralityof peaks 345 with a plurality of recesses 347 and a plurality convexsurfaces 348 interposed with the peaks 345. In one embodiment, therecesses 347 can be curved (e.g., can have a concave curved surface) tocomplement the curved sides S of the articles C and each recess 347 canextend from the adjacent convex surface 348 to the adjacent peak 345 andcan be sized to receive and engage a respective article C (e.g., so thatthe concave surface of the recess 347 extends partially around the sideS of the article).

In the illustrated embodiment, each of the convex surfaces 348 extendsfrom one of the peaks 345 to the adjacent recess 347 and defines anelongate (e.g., relative to the recesses 347), convex curve. In oneembodiment, each convex surface 348 can define a radius of curvature R1that is larger than a radius of curvature R2 defined by the respectiverecesses 347.

As shown in FIG. 9, the combiner wheel 341 has four peaks 345, fourrecesses 347, and four convex surfaces 248. Alternatively, the combinerwheel 341 could have any suitable number of peaks 345, recesses 347, andconvex surfaces 348. As shown in FIG. 10, the second combiner wheel 343is similar to the first combiner wheel 341 except that the firstcombiner wheel 341 is configured for rotating in a counterclockwisedirection CCW and the second combiner wheel 343 is configured forrotating in a clockwise direction CW. Alternatively, one of the combinerwheels 341, 343 could be considered to be upside-down with respect tothe other.

As shown in FIGS. 9 and 10, the combiner wheels 341, 343 rotate onrespective axes 149 and extend into the combination area 359 (e.g.,through slots 351 in the outer lane guides 121 and the gaps formedbetween the plates 373 of the guide brackets 369, 371). In oneembodiment, the combiner wheels 341, 343 are rotated by a motor (notshown) via gears so that the first combiner wheel 341 rotates in thecounterclockwise direction CCW as viewed from above and the secondcombiner wheel 343 rotates in the clockwise direction CW as viewed fromabove as shown in FIGS. 5-12. Accordingly, the peaks 345, the recesses347, and the convex surfaces 348 of the combiner wheels 341, 343 move inthe machine direction M through the combination area 359.

As shown in FIG. 10, the centers of the combiner wheels 341, 343 arealigned on the lateral axis L1 that extends transversely across thewidth of the main conveyor 131, generally perpendicular to the machinedirection M). In the illustrated embodiment, the combiner wheels 341,343 are out of phase with respect to one another, wherein the peak 345of one of the combiner wheels 341, 343 moves through the combinationarea 359 followed by, e.g., at a different point in time than, the peak345 of the opposing combiner wheel 343, 341.

As shown, each of the recesses 347 is opposed by a convex curve 348 ofthe opposing combiner wheel as the recess 347 and the convex curve 348move through the combination area 359, as the convex curve 348 movesthrough the combination area 359 ahead of the respective recess 347 tofacilitate the retention of a respective article CD, CU in therespective recess 347 through the combination area 359. Accordingly, inone embodiment, the first combiner wheel 341 is arranged for engagingand receiving a move a foil down article CD (broadly, “first article”)from the first input lane 107 in the first recess 347 and moving thefirst article CD into the output lane 311, which can be sequentiallyfollowed by a foil up article CU (broadly, “second article”) from thesecond input lane 109 that can be engaged and received by the secondcombiner wheel 343 and moved into the output lane 311 after the firstarticle CD. The lane combiner 301 could be otherwise shaped, positioned,arranged, and/or configured without departing from the disclosure.

In this regard, at a selected moment in time, the first combiner wheel341 can be positioned at a first rotational orientation RP1 about therespective axis 149 in which a first recess 347 of the first combinerwheel 341 is positioned in the combination area 359 and is offset from asecond recess 347 of the second combiner wheel 343 that is positioned inthe combination area 359 when the second combiner wheel 343 ispositioned at a second rotational orientation RP2 about the respectiveaxis 149 that is different from the first rotational orientation RP1. Inone embodiment, when the first recess 347 of the first combiner wheel341 is positioned in the combination area 359, a peak 345 of the secondcombiner wheel 343 extends at least partially across the second inputlane 109. Similarly, in one embodiment, when the first recess 347 of thesecond combiner wheel 343 is positioned in the combination area 359, apeak 345 of the first combiner wheel 341 extends at least partiallyacross the first input lane 107.

In operation, the foil down articles CD move in the first input lane 107from the upstream end 103 of the system 100 along one or both of thelane guides 121, 123 onto the main conveyor 131. Similarly, the foil uparticles CU move in the second input lane 109 from the upstream end 103along one or both of the lane guides 125, 127 onto the main conveyor131. In the illustrated embodiment, as the articles CD, CU move on themain conveyor 131 in the machine direction M, the articles move past thedownstream end of the inner lane guides 123, 127 (e.g., where the innerlane guides 123, 127 converge) and then the foil down articles CD movebetween the outer lane guide 123 and the divider 329 and the foil uparticles CU move between the outer lane guide 125 and the divider 329.

The articles CD, CU continue to move on the main conveyor 131 throughthe lane combiner 301 where the articles CD, CU sequentially andalternatingly engage the combiner wheels 341, 343. In one embodiment,the combination area 359 can be devoid of the divider 329, e.g., adownstream end 363 of the divider 329 can abut or be spaced upstreamfrom the combination area 359.

In one embodiment, one of the foil down articles CD that is adjacent thedownstream end 363 of the divider 329 can engage a recess 347 of thefirst combiner wheel 341 (e.g., see the article CD in position P10 inFIG. 9) while the foil up article CU adjacent the downstream end 363 ofthe divider 329 can engage a convex surface 348 of the second combinerwheel 343 (e.g., see the article CD in position P11 in FIGS. 11 and 12).

As the combiner wheels 341, 343 rotate, the convex surface 348 of thesecond combiner wheel 343 slides against the article CU in the P11position, preventing the articles CU in the second input lane 109 fromadvancing (e.g., due to the motion of the belt 132) into the combinationarea 359 while the article CD in the P10 position is captured by therecess 347 of the first combiner wheel 341, which can move the articleCD into the output lane 311 (e.g., see the article CD in position P12 inFIGS. 11 and 12). As the foil down article CD is moved through thecombination area 359, the subsequent article CD in the input lane 107can engage the convex surface 348 subsequent to the recess 347 thatengaged the article CD in the P10 position. As shown in FIGS. 11 and 12,an article CU in a position P13 is engaged between a recess 347 of thesecond combiner wheel 343 and a convex surface 348 of the combiner wheel341 as the combiner wheels rotate and move the article CU in positionP13 through the combination area 359.

As the combiner wheels 341, 343 rotate to move the articles CD, CU tothe downstream end of the combination area 359, the articles engage thesloped edges 377 of the guide brackets 369, 371, which guide thearticles CD, CU into the output lane 311 as the articles move on thebelt 132 out of the recesses 347 of the combiner wheels 341, 343.

In this regard, the combiner wheels 341, 343 rotate to combine and movethe articles CD,

CU into the output lane 311 so to form the combined plurality ofarticles 112 in which the articles alternate between the foil uparticles CU and the foil down articles CD in sequence. The articles moveon the belt in the output lane 311 in the downstream direction from thelane combiner 301 to the output conveyor 161. In this regard, the system300 can be included in a continuous packaging machine for packaging thearticles C for storage, shipping, sale, etc. For example, the packagingmachine can continuously or substantially continuously feed articles Cto the system 300, which conveys the articles C as described below,which can then be transferred, for example, to a carton or container toform a package.

It will be understood that the above-described operation of the lanecombiner 301 that moves a first article CD from the first input lane 107into the output lane 311 sequentially followed by a second article CUfrom the second input lane 109 can be repeated any desired number oftimes, e.g., such that a third article CD from the first input lane 107is engaged by the first combiner wheel 341 and moved into the outputlane 311 sequentially behind the second article CU and such that afourth article CU from the second input lane 107 is engaged by thesecond combiner wheel 343 and moved into the output lane 311sequentially behind the third article CD, etc.

The above-described systems 100, 300 for receiving the articles C fromtwo inputs with opposing orientations and then combining the inputs intoa single lane so that the articles alternate between the twoorientations can be more reliable and faster than, for example, a systemthat receives the articles in a single input all having the sameorientation and that reorients every other article to achieve an outputwith articles in alternating orientations. For example, such a systemthat is devoid of the lane combiner 101, 301 of the respective systems100, 300 can have problems with reorienting the articles, which can slowthe process and/or result in output that is not consistent in thealternating orientation of the articles, resulting in efficiency losses.In contrast, the systems 100, 300 obviate any need to reorient articlestherealong. Rather, the articles can be input into the second inputlanes 107, 109 and 307, 309 of the respective systems 100 in respectivedesired orientations.

It will be understood that the configuration and arrangement of thecomponents of the systems 100, 300 can be altered without departing fromthe disclosure. In one embodiment, one or more systems 100, 300 can beprovided and run in parallel, for example, to increase output. In oneembodiment, one or both of the systems 100, 300 can be provided with alane combiner that is configured to combine multiple pairs of inputlanes into respective single output lanes in accordance with thediscussion above, and/or can be configured to combine more than twoinput lanes into a single output lane.

Any of the features of the various embodiments of the disclosure can becombined with, replaced by, or otherwise configured with other featuresof other embodiments of the disclosure without departing from the scopeof this disclosure.

The foregoing description of the disclosure illustrates and describesvarious embodiments. As various changes could be made in the aboveconstruction without departing from the scope of the disclosure, it isintended that all matter contained in the above description or shown inthe accompanying drawings shall be interpreted as illustrative and notin a limiting sense. Furthermore, the scope of the present disclosurecovers various modifications, combinations, alterations, etc., of theabove-described embodiments. Additionally, the disclosure shows anddescribes only selected embodiments, but various other combinations,modifications, and environments are within the scope of the disclosureas expressed herein, commensurate with the above teachings, and/orwithin the skill or knowledge of the relevant art. Furthermore, certainfeatures and characteristics of each embodiment may be selectivelyinterchanged and applied to other illustrated and non-illustratedembodiments of the disclosure.

What is claimed is:
 1. A method of conveying articles, comprising:moving a first plurality of articles in a first input lane in adownstream direction to a lane combiner; moving a second plurality ofarticles in a second input lane in the downstream direction to the lanecombiner; and operating the lane combiner to combine the first pluralityof articles and the second plurality of articles into a combinedplurality of articles in an output lane, the operating the lane combinercomprises engaging a first article from the first plurality of articleswith a first combiner wheel, engaging a second article from the secondplurality of articles with a second combiner wheel that is out of phasewith the first combiner wheel, rotating the first combiner wheel to movethe first article into the output lane, rotating the second combinerwheel to move the second article into the output lane after the firstarticle, and the combined plurality of articles comprises the firstarticle and the second article in sequence.
 2. The method of claim 1,wherein the operating the lane combiner further comprises engaging athird article from the first plurality of articles with the firstcombiner wheel, engaging a fourth article from the second plurality ofarticles with the second combiner wheel, rotating the first combinerwheel to move the third article into the output lane after the secondarticle, and rotating the second combiner wheel to move the fourtharticle into the output lane after the third article, the combinedplurality of articles comprises the first article, the second article,the third article, and the fourth article in sequence.
 3. The method ofclaim 1, wherein the first article is in an inverted orientationrelative to the second article.
 4. The method of claim 1, wherein thefirst combiner wheel comprises a plurality of recesses each configuredto receive a respective article of the first plurality of articles, andthe second combiner wheel comprises a plurality of recesses eachconfigured to receive a respective article of the second plurality ofarticles.
 5. The method of claim 4, wherein the plurality of recesses ofthe first combiner wheel are interposed with a plurality of peaks of thefirst combiner wheel, and the plurality of recesses of the secondcombiner wheel are interposed with a plurality of peaks of the secondcombiner wheel.
 6. The method of claim 5, wherein the plurality of peaksof at least one of the first combiner wheel and the second combinerwheel define a respective convex surface with a first radius ofcurvature that is greater than a second radius of curvature of arespective concave surface defined by the plurality of recesses of theat least one of the first combiner wheel and the second combiner wheel.7. The method of claim 4, wherein when a recess of the first combinerwheel is positioned in a combination area of the lane combiner, a peakof the second combiner wheel at least partially extends across thesecond input lane.
 8. The method of claim 1, wherein the first inputlane comprises a first outer lane guide and the second input lanecomprises a second outer lane guide, and a combination area is at leastpartially defined between the first outer lane guide and the secondouter lane guide, the combination area is in communication with each ofthe first input lane, the second input lane, and the output lane.
 9. Themethod of claim 8, wherein the first input lane and the second inputlane are separated by a divider, the combination area is devoid of thedivider.
 10. The method of claim 8, wherein at least a portion of thefirst combiner wheel extends through a slot in the first outer laneguide, and at least a portion of the second combiner wheel extendsthrough a slot in the second outer lane guide.
 11. The method of claim10, wherein the first outer lane guide and the second outer lane guideoverlap a respective first sloped surface and second sloped surface, thefirst sloped surface and the second sloped surface are arranged toconverge toward one another.
 12. The method of claim 11, wherein thefirst sloped surface and the second sloped surface are defined by arespective first lane guide of the output lane and a second lane guideof the output lane.
 13. The method of claim 11, wherein the first slopedsurface and the second sloped surface are defined by a respective firstguide bracket and a second guide bracket.
 14. The method of claim 8,wherein the combination area is positioned upstream relative to theoutput lane.
 15. The method of claim 1, wherein the first combiner wheelrotates about a first rotational axis and the second combiner wheelrotates about a second rotational axis, the first rotational axis isparallel to the first rotational axis.
 16. The method of claim 1,wherein the lane combiner is positioned above a conveyor configured tomove each of the first article and the second article from therespective first input lane and the second input lane, through acombination area, and into the output lane.
 17. A system for conveyingarticles, comprising: a first input lane; a second input lane; and alane combiner positioned downstream from the first input lane and thesecond input lane and comprising a first combiner wheel that is out ofphase with a second combiner wheel, the first combiner wheel ispositioned to engage a first article from a first plurality of articlesin the first output lane and the second combiner wheel is positioned toengage a second article from a second plurality of articles in thesecond input lane, upon out of phase rotation of the first combinerwheel and the second combiner wheel, the first article is moved into theoutput lane and the second article is moved into the output lane afterthe first article to form a combined plurality of articles thatcomprises the first article and second article in sequence.
 18. Thesystem of claim 17, wherein the first article is for being in aninverted orientation relative to the second article.
 19. The system ofclaim 17, wherein the first combiner wheel comprises a plurality ofrecesses each configured to receive a respective article of the firstplurality of articles, and the second combiner wheel comprises aplurality of recesses each configured to receive a respective article ofthe second plurality of articles.
 20. The system of claim 19, whereinthe plurality of recesses of the first combiner wheel are interposedwith a plurality of peaks of the first combiner wheel, and the pluralityof recesses of the second combiner wheel are interposed with a pluralityof peaks of the second combiner wheel.
 21. The system of claim 20,wherein the plurality of peaks of at least one of the first combinerwheel and the second combiner wheel define a respective convex surfacewith a first radius of curvature that is greater than a second radius ofcurvature of a respective concave surface defined by the plurality ofrecesses of the at least one of the first combiner wheel and the secondcombiner wheel.
 22. The system of claim 19, wherein when a recess of thefirst combiner wheel is positioned in a combination area of the lanecombiner, a peak of the second combiner wheel at least partially extendsacross the second input lane.
 23. The system of claim 17, wherein thefirst input lane comprises a first outer lane guide and the second inputlane comprises a second outer lane guide, and a combination area is atleast partially defined between the first outer lane guide and thesecond outer lane guide, the combination area is in communication witheach of the first input lane, the second input lane, and the outputlane.
 24. The system of claim 23, wherein the first input lane and thesecond input lane are separated by a divider, the combination area isdevoid of the divider.
 25. The system of claim 23, wherein at least aportion of the first combiner wheel extends through a slot in the firstouter lane guide, and at least a portion of the second combiner wheelextends through a slot in the second outer lane guide.
 26. The system ofclaim 25, wherein the first outer lane guide and the second outer laneguide overlap a respective first sloped surface and second slopedsurface, the first sloped surface and the second sloped surface arearranged to converge toward one another.
 27. The system of claim 26,wherein the first sloped surface and the second sloped surface aredefined by a respective first lane guide of the output lane and a secondlane guide of the output lane.
 28. The system of claim 26, wherein thefirst sloped surface and the second sloped surface are defined by arespective first guide bracket and a second guide bracket.
 29. Thesystem of claim 23, wherein the combination area is positioned upstreamrelative to the output lane.
 30. The system of claim 17, wherein thefirst combiner wheel rotates about a first rotational axis and thesecond combiner wheel rotates about a second rotational axis, the firstrotational axis is parallel to the first rotational axis.
 31. The systemof claim 17, wherein the lane combiner is positioned above a conveyorconfigured to move each of the first article and the second article fromthe respective first input lane and the second input lane, through acombination area, and into the output lane.
 32. A lane combiner,comprising: a first combiner wheel; and a second combiner wheel that isout of phase with a second combiner wheel; the lane combiner ispositioned downstream from a first input lane and a second input lanesuch that the first combiner wheel is positioned to engage a firstarticle from a first plurality of articles in the first output lane andthe second combiner wheel is positioned to engage a second article froma second plurality of articles in the second input lane, upon out ofphase rotation of the first combiner wheel and the second combinerwheel, the first article is moved into the output lane and the secondarticle is moved into the output lane after the first article to form acombined plurality of articles that comprises the first article andsecond article in sequence.
 33. The lane combiner of claim 32, whereinthe first article is for being in an inverted orientation relative tothe second article.
 34. The lane combiner of claim 32, wherein the firstcombiner wheel comprises a plurality of recesses each configured toreceive a respective article of the first plurality of articles, and thesecond combiner wheel comprises a plurality of recesses each configuredto receive a respective article of the second plurality of articles. 35.The lane combiner of claim 34, wherein the plurality of recesses of thefirst combiner wheel are interposed with a plurality of peaks of thefirst combiner wheel, and the plurality of recesses of the secondcombiner wheel are interposed with a plurality of peaks of the secondcombiner wheel.
 36. The lane combiner of claim 35, wherein the pluralityof peaks of at least one of the first combiner wheel and the secondcombiner wheel define a respective convex surface with a first radius ofcurvature that is greater than a second radius of curvature of arespective concave surface defined by the plurality of recesses of theat least one of the first combiner wheel and the second combiner wheel.37. The lane combiner of claim 34, wherein when a recess of the firstcombiner wheel is positioned in a combination area of the lane combiner,a peak of the second combiner wheel at least partially extends acrossthe second input lane.
 38. The lane combiner of claim 32, wherein atleast a portion of the first combiner wheel extends through a slot in afirst outer lane guide extending along the lane combiner, and at least aportion of the second combiner wheel extends through a slot in a secondouter lane guide extending along the lane combiner.
 39. The lanecombiner of claim 32, wherein the first combiner wheel rotates about afirst rotational axis and the second combiner wheel rotates about asecond rotational axis, the first rotational axis is parallel to thefirst rotational axis.